Shock absorbing material for packaging and deaeration packaging method

ABSTRACT

A styrofoam material  2  is placed in a corrugated carton  1 , and a plastic bag  3  is then loaded into the corrugated carton  1 . Air between any two of the corrugated carton  1 , the styrofoam material  2 , and the plastic bag  3  is evacuated so that the plastic bag  3  is adhered onto dented portions  2   a  for product placement of the styrofoam material  2 , and inner surfaces of the corrugated carton  1 . As a result, products  4  can be easily placed on the styrofoam material  2  onto which the plastic bag  3  is loaded without the products  4  getting snagged on the plastic bag  3  and the plastic bag  3  being torn.

FIELD OF THE INVENTION

The present invention relates to an improvement in a styrofoam materialwhich is used when products are packaged in a corrugated carton, andrelates to a shock absorbing material for packaging and a deaerationpackaging method which make it easy to package products using deaerationetc.

BACKGROUND OF THE INVENTION

There has been provided a related art shock absorbing material forpackaging in which a styrofoam material provided with two or moreoutlets is inserted into a bag-shaped plastic sheet, air in thebag-shaped plastic sheet is sucked out, via the two or more outlets,from an opening of the plastic sheet so that the plastic sheet isadhered to a surface of the styrofoam material, and the opening of theplastic sheet is then closed.

Thus, a shock absorbing material for packaging of high strength can beprovided by coating a styrofoam material with a plastic sheet.Furthermore, forming of two or more inlets in the styrofoam materialmakes it possible to adhere the plastic sheet to a surface of thestyrofoam material efficiently at the time of sucking out the air in theplastic sheet (refer to patent reference 1, for example).

Patent reference 1: JP,2002-337948,A (refer to FIG. 8)

In the related art shock absorbing material for packaging which isconstructed as mentioned above, the styrofoam material is coated withthe plastic sheet in order to increase the strength of the styrofoammaterial, but this structure is not intended for facilitating theprocess of packaging products on the styrofoam material.

There has been also provided, as a related art packaging method, amethod of loading a plastic bag onto a styrofoam material in advance,and placing two or more products on the plastic bag in order to protectproducts to be packaged from the moisture of outside air and to preventchippings of the styrofoam material from being adhered to and mixed intothe products. A problem with the related art packaging method is howeverthat the products will get snagged on the plastic bag when placed on theplastic bag, thereby reducing the workability of the packaging, and thiswill result in tears in the plastic bag.

Therefore, there has been provided a method of placing two or moreproducts on a styrofoam material after individually packaging the two ormore products into plastic bags. A problem with this method ofindividually packaging two or more products into plastic bags is howeverthat it takes a great deal of time, and therefore the workability of thepackaging is reduced.

The present invention is made in order to solve the above-mentionedproblems, and it is therefore an object of the present invention toprovide a shock absorbing material for packaging and a deaerationpackaging method which make it easy to place targets to be packaged onthe shock absorbing material onto-which a thin film member for packagingwhich is thinly formed is loaded without the targets to be packagedgetting snagged on the thin film member for packaging which is thinlyformed and the thin film member being torn when placing the targets tobe packaged on the shock absorbing material for packaging.

DISCLOSURE OF THE INVENTION

A shock absorbing material for packaging in accordance with the presentinvention includes a hole for deaeration which is formed so as topenetrate between a first surface thereof which is brought into contactwith an inner surface of a packaging carton when the shock absorbingmaterial is placed in the packaging carton, and a second surface thereofon which a target to be packed is placed via a thin film member forpackaging which is thinly formed.

Since the shock absorbing material for packaging is thus equipped withthe hole for deaeration which penetrates between the first and secondsurfaces, when the shock absorbing material for packaging is placed inthe packing carton, and air is sucked out from the first surface usingthe deaerating duct after the thin film member for packaging which isthinly formed is loaded onto the second surface of the shock absorbingmaterial for packaging, and into the packing carton, the air between anytwo of the thin film member for packaging which is thinly formed, thesecond surface, and the packing carton is evacuated via the hole fordeaeration, so that the thin film member for packaging which is thinlyformed is adhered to the second surface according to the shape of thesecond surface, and is also adhered to the packing carton.

As a result, the present invention offers an advantage of making it easyto place targets to be packaged on the second surface of the shockabsorbing material onto which the thin film member for packaging whichis thinly formed is loaded without the targets to be packaged gettingsnagged on the thin film member for packaging which is thinly formed andthe thin film member being torn when placing the targets to be packagedon the second surface of the shock absorbing material for packaging.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view showing steps of a deaeration packagingmethod in accordance with embodiment 1 of the present invention;

FIG. 2 is a cross-sectional view showing a problem which arises at atime of loading a plastic bag into a corrugated carton;

FIG. 3 is a cross-sectional view showing a state in which a deaeratingduct is inserted into the corrugated carton when the plastic bag isloaded into the corrugated carton;

FIG. 4 is a cross-sectional view showing a state in which products areplaced in the corrugated carton after air is suck out using thedeaerating duct;

FIG. 5 is a perspective view showing a surface of the styrofoam materialin accordance with embodiment 1 of the present invention;

FIG. 6 is a perspective view showing a surface of a styrofoam materialin accordance with embodiment 2 of the present invention;

FIG. 7 is a perspective view showing a back surface of the styrofoammaterial;

FIG. 8 is a cross-sectional view showing a state in which a deaeratingduct is inserted into a corrugated carton when a plastic bag is loadedinto the corrugated carton;

FIG. 9 is a cross-sectional view-showing a state in accordance withembodiment 3 of the present invention in which a deaerating duct isinserted into a corrugated carton when a plastic bag is loaded into thecorrugated carton; and

FIG. 10 is a cross-sectional view showing a state in which products areplaced in the corrugated carton after air is suck out using a deaeratingnozzle.

PREFERRED EMBODIMENTS OF THE INVENTION

Hereafter, in order to explain this invention in greater detail, thepreferred embodiments of the present invention will be described withreference to the accompanying drawings.

Embodiment 1

FIG. 1 is a perspective view showing steps of a deaeration packagingmethod in accordance with embodiment 1 of the present invention, FIG. 2is a cross-sectional view showing a problem which arises at the time ofloading, for example, a plastic bag which is a thin film member forpackaging which is thinly formed, into a corrugated carton, FIG. 3 is across-sectional view showing a state in which a deaerating duct isinserted into the corrugated carton when the plastic bag is loaded intothe corrugated carton, and FIG. 4 is a cross-sectional view showing astate in which products are placed in the corrugated carton after air issuck out via the deaerating duct.

In the figures, the corrugated carton (i.e., a container) 1 has a lid ona back surface thereof which is fastened with a gummed tape or the like,and has a normal structure. A styrofoam material (i.e., a shockabsorbing material for packaging) 2 has a plurality of dented portions 2a for product placement which are formed in a surface thereof, and isplaced in the corrugated carton 1. After the styrofoam material 2 isplaced in the corrugated carton 1, a plastic bag (i.e., a thin filmmember for packaging which is thinly formed) 3 is loaded onto thestyrofoam material 2 and into the corrugated carton 1. After the plasticbag 3 is adhered onto both the plurality of dented portions 2 a forproduct placement of the styrofoam material 2 and inner surfaces of thecorrugated carton 1, products (i.e., targets to be packaged) 4 areplaced on the plurality of dented portions 2 a for product placement ofthe styrofoam material 2, respectively.

As shown in FIGS. 3 and 4, the deaerating duct 5 is inserted between thecorrugated carton 1 and both the styrofoam material 2 and the plasticbag 3, and the plastic bag 3 is adhered onto both the plurality ofdented portions 2 a for product placement of the styrofoam material 2and inner surfaces of the corrugated carton 1 by sucking out air betweenany two of the corrugated carton 1, the styrofoam material 2, and theplastic bag 3.

As shown in FIG. 5, a circle-shaped penetrating hole (i.e. a hole fordeaeration) 2 b is formed in each of the plurality of dented portions 2a for product placement of the styrofoam material 2. This penetratinghole 2 b is disposed so as to penetrate between a back surface (i.e., afirst surface) 2 c of the styrofoam material 2 which is brought intocontact with a bottom surface 1 a of the corrugated carton 1 when thestyrofoam material 2 is placed in the corrugated carton 1, and a bottomsurface (i.e., a second surface) 2 d of a corresponding dented portionon which a product 4 is placed via the plastic bag 3. In addition topenetrating holes 2 b which are disposed so as to penetrate between theback surface 2 c of the styrofoam material 2, and the bottom surfaces 2d of the plurality of dented portions, a penetrating hole can bedisposed so as to penetrate between an outer lateral surface (i.e., afirst surface) 2 e and an inner lateral surface (i.e., a second surface)2 f of the styrofoam material 2.

A deaerating-duct insertion opening into which the deaerating duct 5 canbe inserted is formed in the lateral surface 2 e of the styrofoammaterial 2 so that the insertion opening is communicated with the backsurface 2 c of the styrofoam material 2.

Next, the steps of the deaeration packaging method in accordance withthis embodiment of the present invention will be explained.

As shown in FIG. 1, the styrofoam material 2 is placed in the corrugatedcarton 1 first (shock absorbing material placing step). This styrofoammaterial 2 buffers vibrations from outside to products 4 which areplaced thereon. The plurality of dented portions 2 a for productplacement are formed in the surface of the styrofoam material 2 so thatsix products 4 can be simultaneously packaged therein.

Next, the plastic bag 3 is loaded onto the styrofoam material 2 and intothe corrugated carton 1 (sheet loading step). This plastic bag 3 isloaded in order to protect the six products 4 from the moisture ofoutside air and to prevent chippings of the styrofoam material 2 frombeing adhered to and mixed into the six products 4.

As shown in FIG. 2, after the plastic bag 3 is loaded onto the styrofoammaterial and into the corrugated carton, if six products 4 are tried tobe placed in the plurality of dented portions 2 a for product placement,respectively, without sucking out the air between any two of thecorrugated carton 1, the styrofoam material 2, and the plastic bag 3,the six products 4 will get snagged on the plastic bag 3 and thereforethe plastic bag 3 will be torn since the plastic bag 3 is not adheredonto the plurality of dented portions 2 a for product placement of thestyrofoam material 2.

In contrast, in accordance with this embodiment 1, the styrofoammaterial 2 is placed in the corrugated carton 1 first, and the plasticbag 3 is loaded onto the styrofoam material 2 and into the corrugatedcarton 1, as shown in FIG. 3. Then, in accordance with this embodiment1, the deaerating duct 5 is inserted into the deaerating-duct insertionopening after the plastic bag 3 is loaded onto the styrofoam materialand into the corrugated carton, and the air between any two of thecorrugated carton 1, the styrofoam material 2, and the plastic bag 3 isevacuated via the plurality of penetration holes 2 b, and space betweenthe bottom surface 1 a of corrugated carton 1 and the back surface 2 cof the styrofoam material 2 by sucking out the air using the deaeratingduct 5, so that the plastic bag 3 is adhered onto the plurality ofdented portions 2 a for product placement of the styrofoam material 2,and inner surfaces of the corrugated carton 1.

Then, as shown in FIG. 4, after the plastic bag 3 is adhered onto theplurality of dented portions 2 a for product placement of the styrofoammaterial 2 and inner surfaces of the corrugated carton 1, six products 4are placed in the plurality of dented portions 2 a for product placementof the styrofoam material 2, respectively.

As mentioned above, in accordance with this embodiment 1, since thestyrofoam material 2 is provided with the plurality of penetrating holes2 b, by placing the styrofoam material 2 in the corrugated carton 1, andsucking out air using the deaerating duct 5 after loading the plasticbag 3 onto the plurality of dented portions 2 a for product placement ofthe styrofoam material 2 and into the corrugated carton 1, the airbetween the plastic bag 3 and the styrofoam material 2 is evacuated viathe plurality of penetrating holes 2 b so that the plastic bag 3 isadhered onto the plurality of dented portions 2 a for product placementaccording to their shape and also onto the corrugated carton 1. As aresult, products 4 can be easily placed in the plurality of dentedportions 2 a for product placement of the styrofoam material 2 ontowhich the plastic bag 3 is loaded without the products 4 getting snaggedon the plastic bag 3 and the plastic bag 3 being torn.

In addition, since the styrofoam material has the deaerating-ductinsertion opening 2 g, the deaerating duct 5 can be easily insertedbetween the plastic bag 3 and the styrofoam material 2 via thedeaerating-duct insertion opening 2 g in order to suck out the airbetween the plastic bag 3 and the styrofoam material 2 via the pluralityof penetrating holes 2 b and space between the bottom surface 1 a of thecorrugated carton 1 and the back surface 2 c of the styrofoam material 2by using the deaerating duct 5, thereby increasing the efficiency ofdeaeration.

Embodiment 2

FIG. 6 is a perspective view showing a surface of a styrofoam materialin accordance with embodiment 2 of the present invention, FIG. 7 is aperspective view showing a back surface of the styrofoam material, andFIG. 8 is a cross-sectional view showing a state in which a deaeratingduct is inserted when a plastic bag is loaded into a corrugated carton.

As shown in FIGS. 6 to 8, rectangle-shaped penetrating holes (i.e.,holes for deaeration) 2 h are formed on both sides of a bottom surface 2d of each of a plurality of dented portions 2 a for product placement ofthe styrofoam material 2. These penetrating holes 2 h are disposed so asto penetrate between a back surface (i.e., a first surface) 2 c of thestyrofoam material 2 which is brought into contact with a bottom surface1 a of the corrugated carton 1 when the styrofoam material 2 is placedin the corrugated carton 1, and a bottom surface (i.e., a secondsurface) 2 d of a corresponding dented portion on which a product 4 isplaced via the plastic bag 3. In addition to penetrating holes 2 b whichare disposed so as to penetrate between the back surface 2 c of thestyrofoam material 2, and the bottom surfaces 2 d of the plurality ofdented portions, a penetrating hole can be disposed so as to penetratebetween an outer lateral surface (i.e., a first surface) 2 e and aninner lateral surface (i.e., a second surface) 2 f of the styrofoammaterial 2.

Grooves (i.e., grooves for deaeration) 2 i which provide communicationbetween a deaerating-duct insertion opening 2 g and the penetratingholes 2 h are formed in the back surface 2 c of the styrofoam material2.

The other structure of the styrofoam material is the same as that shownin FIGS. 3 and 4.

Next, steps of a deaeration packaging method in accordance with thisembodiment of the present invention will be explained.

As shown in FIGS. 6 to 8, the styrofoam material 2 is placed in thecorrugated carton 1 first, and the plastic bag 3 is loaded onto thestyrofoam material 2 and into the corrugated carton 1. Then, thedeaerating duct 5 is inserted into the deaerating-duct insertion opening2 g after the plastic bag 3 is loaded onto the styrofoam material andinto the corrugated carton, and air between any two of the corrugatedcarton 1, the styrofoam material 2, and the plastic bag 3 is evacuatedvia the plurality of penetration holes 2 b, and space between the bottomsurface 1 a of the corrugated carton 1 and the grooves 2 i of thestyrofoam material 2 by sucking out the air using the deaerating duct 5,so that the plastic bag 3 is adhered onto the plurality of dentedportions 2 a for product placement of the styrofoam material 2, andinner surfaces of the corrugated carton 1.

Then, after the plastic bag 3 is adhered onto the plurality of dentedportions 2 a for product placement of the styrofoam material 2 and innersurfaces of the corrugated carton 1, six products 4 are placed in theplurality of dented portions 2 a for product placement of the styrofoammaterial 2, respectively.

As mentioned above, in accordance with this embodiment 2, since the twopenetrating holes 2 d are formed in the both sides of the bottom surface2 d of each of the plurality of dented portions 2 a for productplacement of the styrofoam material 2, the air between any two of thecorrugated carton, the styrofoam material, and the plastic bag isevacuated from the both sides of each of the plurality of dentedportions 2 a for product placement on a priority basis when the air issucked out using the deaerating duct 5. Therefore, this embodiment canprevent air from remaining in the vicinity of the both sides of each ofthe plurality of dented portions 2 a for product placement, therebyincreasing the degree of adhesion with the plastic bag 3 in the vicinityof the both sides of each of the plurality of dented portions 2 a.

Since the grooves 2 i providing communication between thedeaerating-duct insertion opening 2 g and the plurality of penetratingholes 2 h are formed in the back surface of the styrofoam material, theair between any two of the corrugated carton, the styrofoam material,and the plastic bag can be evacuated through space between the grooves 2i which are communicated with the penetrating holes 2 h, and the bottomsurface 1 a of the corrugated carton 1 when the air is sucked out usingthe deaerating duct 5, thereby increasing the efficiency of deaeration.

The efficiency of deaeration can be further increased by adjusting anddetermining the positions, shapes, and sizes of the penetrating holes 2h, and the routes and sizes of the grooves 2 i according todetermination of the shape of the plurality of dented portions 2 a forproduct placement of the styrofoam material 2. In the illustratedexample, the grooves 2 i are formed only in the back surface (i.e., thefirst surface) of the styrofoam material 2 which is brought into contactwith the bottom surface 1 a of the corrugated carton 1. As analternative, the grooves 2 i can be formed in the bottom surfaces (i.e.,the second surfaces) of the plurality of dented portions 2 a, or in boththe first and second surfaces.

Embodiment 3

FIG. 9 is a cross-sectional view showing a state in accordance withembodiment 3 of the present invention in which a deaerating nozzle isinserted into a corrugated carton when a plastic bag is loaded into thecorrugated carton, and FIG. 10 is a cross-sectional view showing a statein which products are placed in the corrugated carton after air is suckout using the deaerating nozzle.

As shown in FIGS. 9 and 10, insertion holes 1 c are formed in a bottomsurface 1 a of the corrugated carton 1 and at positions respectivelycorresponding to those of penetrating holes 2 b of a styrofoam material2 which is to be placed on the bottom surface 1 a of the corrugatedcarton 1. A deaerating duct 5 includes deaerating nozzles 5 a formedthereon and at positions respectively corresponding to those of theinsertion holes 1 c of the corrugated carton.

The other structure of the styrofoam material is the same as that shownin FIGS. 3 and 4.

Next, steps of a deaeration packaging method in accordance with thisembodiment of the present invention will be explained.

As shown in FIG. 9, the styrofoam material 2 is placed in the corrugatedcarton 1 first, and the plastic bag 3 is loaded onto the styrofoammaterial 2 and into the corrugated carton 1. Then, in accordance withthis embodiment 3, after the plastic bag 3 is loaded onto the styrofoammaterial and into the corrugated carton, the deaerating nozzles 5 a ofthe deaerating duct 5 are inserted from the back surface 1 b of thecorrugated carton 1 into the penetrating holes 2 b of the styrofoammaterial 2 via the insertion holes 1 c of the corrugated carton 1,respectively, and air between any two of the corrugated carton 1, thestyrofoam material 2, and the plastic bag 3 is then evacuated via thepenetrating holes 2 b by sucking out the air using the deaerating duct5, so that the plastic bag 3 is adhered onto a plurality of dentedportions 2 a for product placement of the styrofoam material 2, andinner surfaces of the corrugated carton 1.

Then, as shown in FIG. 10, after the plastic bag 3 is adhered onto theplurality of dented portions 2 a for product placement of the styrofoammaterial 2 and inner surfaces of the corrugated carton 1, six products 4are placed in the plurality of dented portions 2 a for product placementof the styrofoam material 2, respectively.

As mentioned above, in accordance with this embodiment 3, the deaeratingnozzles 5 a of the deaerating duct 5 are inserted from the back surface1 b of the corrugated carton 1 into the penetrating holes 2 b of thestyrofoam material 2 via the insertion holes 1 c of the corrugatedcarton 1, respectively, and the air between any two of the corrugatedcarton, the styrofoam material, and the plastic bag is evacuated.Therefore, the deaerating nozzles 5 a can be easily inserted intopenetrating holes of the styrofoam material and the deaeration can beeasily performed without the deaerating nozzles 5 a being caught betweenthe plastic bag 3 and the corrugated carton 1.

In accordance with above-mentioned embodiment 3, the styrofoam material2 has the penetrating holes 2 b which are circle-shaped as shown inabove-mentioned embodiment 1. As an alternative, the styrofoam material2 can have penetrating holes 2 h which are formed on both sides of abottom surface 2 d of each of the plurality of dented portions 2 a forproduct placement, as shown in above-mentioned embodiment 2. In thiscase, the deaeration can be easily performed by using a deaerating duct5 having a plurality of deaerating nozzles 5 a whose positions aredetermined so as to correspond to those of the penetrating holes 2 h.

By forming the deaerating nozzles 5 a of the deaerating duct so thatthey are thin, have a large strength, and are sharp, like hypodermicneedles, and inserting these deaerating nozzles directly into the backsurface 1 b of the corrugated carton 1, the deaeration can be alsoperformed. In this case, since it is not necessary to form any insertionholes 1 c in the bottom surface 1 a of the corrugated carton 1, and thedeaerating nozzles are thin, holes which are formed in the back surfaceof the corrugated carton by the insertion of the deaerating nozzles canbe reduced in size and can be made inconspicuous.

INDUSTRIAL APPLICABILITY

As mentioned above, the shock absorbing material for packaging anddeaeration packaging method in accordance with the present invention aresuitable for facilitating packaging of products using deaeration whenpackaging the products in a corrugated carton.

1. A packaging system comprising: a packaging carton; a single padformed of shock absorbing material; and a deaerating-duct havingdeaerating nozzles formed thereon for sucking air, wherein a pluralityof holes for deaeration is formed so as to penetrate through a firstsurface of the single pad, which is brought into contact with an innersurface of said packaging carton when said single pad is placed in saidpackaging carton, wherein said plurality of holes for deaeration is alsoformed so as to penetrate through a second surface of the single pad onwhich a product to be packed is placed via a thin film member, whereinsaid nozzles are inserted into said plurality of holes for deaerationvia a deaerating-duct insertion openings formed through said packagingcarton, wherein said deaerating-duct is provided under a bottom surfaceof said packaging carton, such that said deaerating duct is providedoutside of said packaging carton, and wherein said deaerating-ductinsertion openings are formed through said bottom surface of saidpackaging carton.
 2. The packaging system according to claim 1, whereinthe plurality of holes for deaeration are formed on a side of a dentedportion provided in the second surface, the dented portion for placementof the product.
 3. The packaging system according to claim 1, furthercomprising at least one dented portion in the second surface, the dentedportion for placement of the product therein, wherein at least two holesfor deaeration are formed in the dented portion.
 4. The packaging systemaccording to claim 1, wherein the plurality of holes are enclosed withinthe shock absorbing material.
 5. The packaging system according to claim1, wherein the plurality of holes are fully enclosed by the shockabsorbing material around the perimeter of the holes.
 6. The packagingsystem according to claim 1, wherein positions of said plurality ofholes for deaeration correspond, respectively, to positions of saiddeaerating-duct insertion openings formed through said packaging carton.